1-compile process safety
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Occupational Safety and Health 5
Safety: Strategy of Accident Prevention
Loss Prevention: Prevention of accidents
which result in injury to humans, damage to
the environment, loss of production, damage
to equipment, or loss of inventory as well as
to protect company reputation and bussiness.
Definitions
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Occupational Safety and Health 6
Ammonium Nitrate Explosion in
Toulouse - France
21 September 2001
• 31 People Killed
• 2442 Injured
• Losses in Hundreds of
millions dollars
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Occupational Safety and Health 7
Regulatory Concerns
OSHA - Occupational Safety and Health Administration
Force of law with respect to on-site workplace hazards / accidents.
OSHA 1910.119 - Process Safety Management
- Must identify hazards
- Must train and certify workers
- Safe work system
- Management of Change
- Accident investigations
- Process Info / Documentation
- Contractor safety
- Operating procedures
- Mechanical integrity
- Others
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Hazard
Hazard adalah suatu kondisi dimana secara kimia ataupun fisik yang memiliki potensi dapat membahayakan terhadap manusia, properti maupun lingkungan
Hazard Evaluation/ Evaluasi bahaya adalah suatu usaha yang terorganisir untuk mengidentifikasi dan menganalisa situasi yang berbahaya dan signifikan serta terasosiasi dengan sebuah proses atau aktifitas. Evaluasi Bahaya ini digunakan untuk menunjukkan dengan tepat kelemahan dalam suatu rancangan dan operasional dari fasilitas yang dapat menyebabkan terilisnya bahan berbahaya, kebakaran maupun terjadinya ledakan.
• Process hazard(s) analysis • Hazard and risk analysis • Process hazard(s) review • Hazard assessment • Hazard identification and • Predictive hazard evaluation
• Process safety review • Process risk survey • risk analysis • Process risk review . • Hazard study
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Proses Safety Management (PSM) :
1 • Identifikasi hazard
2
• Pemilihan teknik Hazard Evaluation yang tepat sesuai kebutuhan
3 • Penggunaan Metode Tertentu
4 • Penindaklanjutan hasil Hazard Evaluation
Evaluasi bahaya biasanya fokus pada penyebab potensial dan konsekuensi dari peristiwa episodik, seperti kebakaran, ledakan, dan rilis yang tidak direncanakan dari bahan berbahaya
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Aspek Aspek dari Pemahaman Resiko
Implementasi program PSM dapat membantu organisasi memanage resiko pada seluruh fasilitasnya sepanjang umur perusahaannya. Pengembangan untuk pemahaman dari resiko membutuhkan 3 pertanyaan spesifik seperti terangkum dalam diagram berikut :
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Elements of process incidents
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Anatomy of a catastrophic incident
Dalam kondisi operation mode “Normal” semua proses hazards aman dan terkendali dan fasilitas beroperasi dalam batasan dan sesuai dengan prosedur operasi yang ada
Penyebab awal atau initiating cause merupakan suatu bentuk perlaihan mode operasi dari kondisi normal menjadi abnormal. Dalam konteks prosedur evaluasi bahaya, ini modus yang abnormal ini disebut deviasi
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Key Concept : The Loss Event
“Loss Event” adalah suatu periode tertentu di dalam “incident sequence” dimana kejadian fisik yang tidak diperbaiki atau “irreversible physical event” terjadi dan mempunyai potensi kehilangan dan akibat yang fatal.
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Untuk mempermudah identifikasi initiating cause dan loss event’ dapat dituangkan dalam insident sequence seperti gambar berikut :
Initiating cause adalah transisi dari mode operasi Normal ke Abnormal dan Loss Event adalah transisi dari mode operasi Normal ke Emergency.
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The Role of Safeguards
Dalam konteks prosedur evaluasi hazard, setiap perlatan, sistem maupun tindakan yang dapat mencegah rantai kejadian (chain of event) yang setelah adanya initiating cause disebut Safeguard.
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Hazard
• Hazards are contained by multiple protective barriers
• Barriers may have weaknesses or ‘holes’
• When holes align hazard energy is released, resulting in the potential for harm
• Barriers may be physical engineered containment or behavioral controls dependent on people
• Holes can be latent/incipient, or actively opened by people
Accident
Protective
‘Barriers’
Weaknesses
Or ‘Holes’
HAZARD PROTECTION
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Protective and Responsive Protection
1
2
4
56
3
PREVENTION
BARRIERSRECOVERY
BARRIERS
LocationTop Event(eg Loss of
Containment)
ConsequenceCondensate pool on water
(Environmental Spill)
Barrier (eg High Level Trip)
Barrier (eg PSV)
Barrier (eg Designed to
Code)
Threat
(eg Slugging)
Threat
(eg Blocked Outlet)
Threat
(eg Corrosion)
Hazard
(eg Condensate)
Location
Top Event
(eg Loss of
Containment)
Barrier (eg Ignition Control)
Barrier (eg Fire Detection &
ESD)
Barrier (eg Bund)
Consequence
(eg Unignited
Condensate release)
Consequence
(eg Fire [Spray/Pool/
Flash] & Explosion)
Consequence
(eg Condensate Pool
– Environmental Spill)
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19
• In modern plants,
process safety relies
on the principle of
multiple protection
layers; Typical
layers of protection
in a modern
chemical plant .
• Each layer of
protection consists
of a grouping of
equipment and/or
human actions,
shown in the order
of activation.
Multiple Protection
Layers
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Onsite Risk Criteria
10-3 per year
10-5 per year
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Hazard Evaluation Throughout a Plant Lifetime
Dua aspek evaluasi bahaya selama masa hidup plant/pabrik • Dengan menggunakan pendekatan life cycle dalam hubungan dengan kegiatan
Process safety management (PSM) lainnya secara efisien dapat mengungkapkan kekurangan dalam desain dan operasi sebelum unit ini ditempatkan, dibangun atau dioperasikan, sehingga membuat penggunaan sumber daya menjadi efektif yang ditujukan untuk menjamin keaman dan produktifitas dari fasilitas.
• Terlepas dari teknik yang digunakan untuk melakukan evaluasi bahaya sepanjang masa operasi fasilitas, masing-masing studi, bersama dengan informasi yang didokumentasikan dan asumsi, harus diperbarui atau divalidasi ulang secara periodik
Semua pendekatan process safety management (PSM) secara konsisten mengacu pada : “Evaluasi hazard harus dilakukan sepanjang umur dari fasilitas”. Hazard evaluation dimulai sejak • Tahap Research and Development • Detailed rancangan dan konstruksi • Selama commisioning dan start up • Secara periodik sepanjang usia operasi • Sampai proses dihentikan.
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Proccess Safety Overview
1.What is process safety?
2. Opposite of process safety : Major incidents
3. The anatomy of process safety incidents
4. Oveview of process safety strategies
5. Taking advantage of past experience
6. Defense in depth/layers or protection
7. Elements of process safety management
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Process Safety
the absence of loss and harm resulting from fires, explosions and hazardous material releases at process facilities.
The absence of loss and harm at process facilities by:
(a). Identifying process hazards,
(b). Containing and controlling them
(c). Countering abnormal situations with effective safeguards
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Major Process incidents
Flixbrough,UK (June 1974)
• Partial oxidation of cyclohexane
• Catastrophic failure of temporary piping
• 30 tonnes of ht cyclohexane released in 30 s
• Vapor cloud explosion
• 28 fatalities, 53 injuries, 1.800+houses damaged;plant destroyed
• 18 of those fatally injured were in control room
• Hastened passage of UK “Healthy and Safety at Work Act”
See CCPS 2008b for details of these incidents
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MAJOR PROCESS INCIDENTS
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Incident - Definition
Incident: An unplanned event or sequence of events that either resulted in, or had the potential to result in, adverse impacts.
Process safety incident anatomy
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Process Industry Incidents
Fires - Fatalities
Explosions - Injuries
Toxic releases - Environ. Damage
- Property Damage
- Evacuations
- Business Losses
- Plant Closings
- fines, Lawsuits
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Process Industry Incidents
Loss - Fatalities Events - Injuries
- Environ.Damage
- Property Damage
- Evacuations
- Business Losses
- Plant Closings
- Fines, Lawsuits
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Process industry incidents
Loss Events
Impact
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Key definition
Loss event:
Point in time in an abnormal situation when an irreversible physical event occurs that has the potential for loss and harm impacts.
Point in time in an abnormal situation when an irreversible physical event occurs that has the potential for loss and harm impacts.
Examples :
Hazardous material release
Flammable vapor or.dust cloud ignition
Tank or vessel overpressurization ruptur
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Key questions Why do loss events happen? How do loss events happen? What must be done to avoid them?
Why do loss events happen?
We choose to handle dangerous process materials and energies
• To make a living • To provide society with desiable
product As long as we choose to handle
them, a potential for loss events exitss
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Process safety
The absence of loss and harm at process facilities by (a) Identifying process hazards, (b) Containing and controlling them, (c) Countering abnormal situations with effective
safeguards
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Process hazard - definition
Presence of a stored or connected material or energy with inherent characteristics having the potential for causing loss or harm
3 types of process hazards
Material hazards
Energy hazards
Chemical interaction hazards
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3 types of process hazards
Material hazards : A contained or connected process material with one more hazardous characteristics
Energy hazards : some form of physical energy contained within or connected to the process with the potential for loss or harm
Chemical interaction hazards : presence or material with the potential for loss or harm upon their interaction in an unintentional or uncontrolled manner
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Inherent characteristics
Presence of a stored or connected material or energy with inherent characteristics having the pootential for causing loss or harm
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Material hazards
Inherently hazardous characteristics :
Flammability Insability
Toxicity Corrosivity
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Flammable materials
Inherent characteristics : > Flash point ( volatility) > Heat of combustion > Ease of ignition . Flammability ignition limits . Minimum ignition energy . Autoignition temperature
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Limitations
NFPA 704 diamonds and SDSs only give properties of individual hazardous materia
. Hazardous energies not identified . Some hazardous chemical interactions not identified . Connected hazards may not be identified
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Process hazard
Presence of a stored or connected material or energy with inherent characteristics having the pootential for causing loss or harm
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process hazard
Presence of a stored or connected material or energy with inherent characteristics having the pootential for causing loss or harm
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Degree of hazard
More hazardous material
greater degree of hazard
farther from zero energy state
greater degree of hazard
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Key questions
Why do loss events happen? How do loss events happen? What must be done to avoid them?
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How do loss events happen?
Anatomy of an incident
Unsafe act & condition precursors
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Incident sequence : Hazard
During normal operation,
all hazards are contained
and controlled
Normal operation
During normal operation,
all hazards are contained
and controlled , but they
are still present.
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Incident sequence : cause Every incident start with an initiating cause (also called an initiating event or just a “cause”.
Example initiating cause:
- feed pump fails off
- procedural step omitted
- truck runs into process piping
- wrong raw material is received
- extreme low ambient temperature
Once an initiating cause accurs, normal operation cannot continue without a process or operational response.
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Incident sequence : Deviation
The immediate result of an initiating cause is a deviation
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Abnormal situations Most engineering focuses on designing a process to work : (normal situation) We must also consider how a process can fail , starting with an “abnormal situation”
Incident sequence : Deviation
A deviation is an abnormal situation, outside defined design or operational parameter.
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Incident sequence : Loss event A loss event will result if a deviation continues uncorrected and the process is not shut down
Loss events are generally irreversible process material/energy reases.
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Incident sequence : Impacts Impacts are the losses and injuries that can result from a loss event.
There are often other less tangible impacts as well
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Incident sequence without safeguards
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How do loss events occur?
Anatomy of an Incident
Unsafe act & condition precursors
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Unsafe act & condition precursors
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Pyramid principle of safey
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Pyramid principle of safety
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Pyramid principle of safety
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Process safety Overview 1.What is process safety? 2.Opposite of process safety : Major incident 3.The anatomy of process safety incidents 4.Overview of process safety strategies 5.Taking advantage of past experience What 6.Defence in depth/layers of protection must be 7. Elements of process safety management done
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Process safety Overview
1.What is process safety?
2.Opposite of process safety : Major incident
3.The anatomy of process safety incidents
4.Overview of process safety strategies
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Using past experience “Those who cannot remember the past are condemned to repeat it.”- George Santayana Learnings from past (usually bad) experiences have been
embodied in various forms: Regulations - Handbooks Codes - Guidelines Industry standards - Procedures Company standards - checklists “”Best practices” - Supplier Recommendations
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RAGAGEPs Recognized and Generally Accepted Good Engineering Practices • Take advantage of wealth of experience • Pass on accumulated knowledge • Reduce recurrence of past incidents • Enable uniformity of experience of expectations • Reduce liabilities when followed
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Example : Anhydrous ammonia Regulatory requirements : E.g. U.S.OSHA Standard 29 CFR 1910.111. “Storage and Handling of Anhydrous Ammonia” Industry standards CGA G-2.”Anhydrous Ammonia” ANSI/CGA K61.1.”American National Standard Safety requirement for the Storage and Handling of Anhydrous Ammonia” Other standards apply to specific applications,e.g.,EN 378 for ammonia
refrigeration
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Layers of protection Also called “safety layers” Multiple layers may be needed.since no protection is
100%reliable Each later must be designed to be effective Each layer must be maintained to be effective some layer of protection are contain and control
measures Other layers of protection are safeguards
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Layers of protection Also called “safety layers” Multiple layers may be needed.since no protection is
100%reliable Each later must be designed to be effective Each layer must be maintained to be effective Some layer of protection are contain and control
measures Other layers of protection are safeguards
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Key definition
Safeguard: Any device ,system, or action that would likely interrupt the chain of events following an initiating cause or that would mitigate loss event impacts/
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Process safety Overview 1.What is process safety?
2.Opposite of process safety : Major incident
3.The anatomy of process safety incidents
4.Overview of process safety strategies
5.Taking advantage of past experience
6.Defence in depth/layers of protection
7. Element of process safety management
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Comprehensive PSM program elements
Management systems
Employee participation
Process safety information
Process hazard analysis
Operating precedures
Training
Contractor safety
• Pre-startup safety reviews
• Mechanical integrity
• Safety work practies
• Management of change
• Emergency planning and response
• Incident investigation
• Compliance audits
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PSM elements covered in this course
Management systems
Employee participation
Process safety information
Process hazard analysis
Operating precedures
Training
Contractor safety
• Pre-startup safety reviews
• Mechanical integrity
• Safety work practies
• Management of change
• Emergency planning and response
• Incident investigation
• Compliance audits